In food processing facilities, maintaining both hygiene and efficiency in production lines is critical. Conveyor belt cleaning systems are essential in food processing facilities to maintain hygiene and efficiency. A global manufacturer of high-quality chocolate and cocoa products was facing persistent carryback of chocolate sludge on its conveyor belts, idlers, and rollers — causing frequent downtime and labour-intensive cleaning. A variety of conveyor belt cleaning systems and types are available to address different materials and operational needs.

This case study explores how the Flexco FGP Food Grade Belt Cleaner, supplied and implemented by SLS Bearings in collaboration with Flexco Singapore, transformed the manufacturer’s conveyor belt systems. The conveyor belt cleaners, made from food-grade material and compliant with FDA standards, significantly reduced carryback, extended cleaning intervals, and enhanced overall plant efficiency while maintaining strict hygiene standards.

In the food processing facilities, viscous chocolate residues frequently adhered to the belt’s return side, causing operational inefficiencies and hygiene concerns.

Key issues included:

•  Excessive carryback leading to frequent stoppages.
• Time-consuming cleaning of equipment to remove sludge build-up.
• Productivity loss and higher labour costs.
• Frequent clean up required due to carryback accumulating on the belt and surrounding areas.
  

The chocolate manufacturer needed a reliable, food-grade solution that could meet strict hygiene standards while improving production efficiency. The belt and its components require regular maintenance to ensure optimal performance and reduce the need for ongoing clean up.

The SLS Bearings technical team collaborated with Flexco Singapore to assess the facility’s conveyor system and identify an effective belt-cleaning solution. Multiple site visits were conducted to study the material behaviour, belt conditions, and sanitation requirements unique to chocolate handling.

Through these evaluations, the team determined that the Flexco FGP Food Grade Belt Cleaner offered the right balance of cleaning efficiency, hygiene compliance, and ease of maintenance. The cleaning system can be configured with different designs to suit specific production needs. Designed specifically for food manufacturing, the FGP Food Grade Belt Cleaner features stainless-steel construction, food-safe material, and a quick-release design that allows fast disassembly for cleaning without compromising belt integrity or production uptime. 

Before installation, the SLS Bearings team conducted several joint site surveys with Flexco Singapore to assess the conveyor system’s operating conditions and material behaviour. These assessments provided valuable insight into the chocolate carryback issues, belt configurations, and hygiene requirements of the production environment. This process allowed the teams to recommend a targeted, food-grade solution suited for the facility’s needs.

After the evaluations, a one-month performance trial was carried out under real production conditions. During this period, the SLS and Flexco technical teams closely monitored the system, evaluating carryback reduction, cleaning effectiveness, and overall reliability. Installation was completed with full on-site support, including operator guidance to ensure smooth integration and minimal disruption to production.

The trial results were carefully recorded, and after confirming significant improvements in belt cleanliness and reduced maintenance, the client expanded the installation across multiple production lines. Throughout the process, SLS Bearings continued to provide technical support, ensuring each belt cleaner operated efficiently and consistently to maintain high productivity and hygiene standards.

After installation, the food manufacturing facility’s conveyor belts saw a 70% drop in carryback. The cleaning frequency changed from weekly to about once every 12 days.

Belts, idlers, and rollers remained cleaner for longer periods, resulting in:

• Shorter maintenance downtime.
• Reduced labour costs.
• Improved hygiene and work efficiency.
• Maintaining the belt in optimal condition reduces the risk of material build-up and prolongs equipment life.

The customer was satisfied with the results. They decided to expand the installation of belt cleaners to more production lines to standardise performance and reliability.

The positive results clearly demonstrated the value of implementing the right belt cleaning solutions and how the Flexco FGP Food Grade Belt Cleaner is a reliable solution for handling various materials on the belt. With cleaner belts, reduced downtime, and improved safety, the client experienced measurable benefits that directly supported their productivity goals. The biggest impact was on the daily work of the operators. They experienced easier maintenance, safer working conditions, and smoother operations.

The success of this project reflected the close collaboration between SLS Bearings, Flexco Singapore, and the client’s engineering team. From consultation to installation, SLS provided ongoing technical guidance to ensure optimal performance and long-term reliability.

“We are pleased with the performance of the Flexco FGP Food Grade Belt Cleaner. It has greatly reduced carryback and lessened the cleaning needed on our production lines. This helps us improve productivity and efficiency.”

At SLS Bearings, we are committed to helping customers achieve higher efficiency, safety, and productivity through reliable solutions. By partnering with Flexco Singapore, we delivered proven food-grade conveyor belt cleaning solutions that improved hygiene, reduced downtime, and supported sustainable operational excellence.

Get in touch with us to explore our tailored solutions that enhance efficiency, reliability, and performance in your operations.